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US20100112505A1 - Method and apparatus for processing oil drilling waste - Google Patents

Method and apparatus for processing oil drilling waste Download PDF

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Publication number
US20100112505A1
US20100112505A1 US12/442,891 US44289107A US2010112505A1 US 20100112505 A1 US20100112505 A1 US 20100112505A1 US 44289107 A US44289107 A US 44289107A US 2010112505 A1 US2010112505 A1 US 2010112505A1
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United States
Prior art keywords
oil drilling
drilling waste
kiln
granules
waste
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Abandoned
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US12/442,891
Inventor
Antero Pulkkanen
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Migliore Oy
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Migliore Oy
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Assigned to MIGLIORE OY reassignment MIGLIORE OY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PULKKANEN, ANTERO
Publication of US20100112505A1 publication Critical patent/US20100112505A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/023—Fired or melted materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/20—Agglomeration, binding or encapsulation of solid waste
    • B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/20—Agglomeration, binding or encapsulation of solid waste
    • B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
    • B09B3/29—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix involving a melting or softening step
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/10—Clay
    • C04B14/12—Expanded clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/0481—Other specific industrial waste materials not provided for elsewhere in C04B18/00
    • C04B18/049—Wastes from oil or other wells, e.g. drilling mud
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/20—Waste materials; Refuse organic from macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/02—Treatment
    • C04B20/04—Heat treatment
    • C04B20/06—Expanding clay, perlite, vermiculite or like granular materials
    • C04B20/061—Expanding clay, perlite, vermiculite or like granular materials in rotary kilns
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/04—Clay; Kaolin
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/1325—Hazardous waste other than combustion residues
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62695—Granulation or pelletising
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
    • E21B21/06—Arrangements for treating drilling fluids outside the borehole
    • E21B21/068—Arrangements for treating drilling fluids outside the borehole using chemical treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/20—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having rotating or oscillating drums
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/14—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of contaminated soil, e.g. by oil
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2209/00—Specific waste
    • F23G2209/24—Contaminated soil; foundry sand
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2900/00—Special features of, or arrangements for incinerators
    • F23G2900/70—Incinerating particular products or waste
    • F23G2900/7013—Incinerating oil shales
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention concerns a method defined in the preamble of claim 1 for processing oil drilling waste as well as an apparatus defined in the preamble of claim 12 .
  • drilling fluid or lubricant is used, producing contaminated drilling waste that has been previously subjected to centrifuging or, treatment with heat at a temperature of less than 800° C. in order to purify it.
  • the oil drilling waste of each object contains rock material and clay material in a ratio typical of each object.
  • the objective of the invention is to eliminate the disadvantages referred to above.
  • One specific objective of the invention is to disclose a new type of method and apparatus for processing the rock and clay-based material produced in oil drilling.
  • the invention is based on a method for processing oil drilling waste, especially for its further processing for the purposes of recycling.
  • oil drilling waste of one or more types is selected, which wastes are introduced into a rotating kiln; in the kiln the oil drilling waste is processed, i.e. burned, at a temperature of 1100 to 1350° C. to form recyclable granules or granulates having a compact-coated, e.g. glazed, surface.
  • agents harmful to the environment are removed; that is, they transform into another, chemically more harmless form and/or are adsorbed within the granular structure, meaning that the granules are neutralized with respect to the environmental detriments.
  • a compact-coated surface such as a glazed surface is achieved for the granules.
  • oil drilling waste contains a rock derivative/rock derivatives; oil-based drilling fluid known per se; and in some cases also crude oil.
  • the rock derivative may have been chosen from one of the following: illite, chlorite, kaolin, montmorillonite, chalkstone, sandstone, anhydrite, dolomite, calcite, or the like.
  • the oil drilling waste is mixed to form a homogenous mixture prior to introducing into a rotating kiln.
  • Mixing the agents to be processed to form a homogenous mixture prior to a combustion process increases the formation of granules with a uniform composition.
  • the oil drilling waste is processed in the kiln at a temperature of 1120 to 1200° C.
  • the oil drilling waste is processed in the kiln at a temperature of about 1130 to 1150° C. In one embodiment, the oil drilling waste is processed in the kiln at a temperature of more than 1150° C. to increase the adherence of the granules to one another.
  • the granules can be used e.g. directly in various cast use possibilities, including road soil, soil of storage areas, soil of pipelines, security areas of processes, and basins, or the like.
  • the oil drilling waste may contain 0 to 100% of rock material and/or 0 to 100% of clay material. In one embodiment, the oil drilling waste contains up to 70 to 100% of rock material and up to 30% of clay material.
  • claybased material is added to the oil drilling waste.
  • clay material such as marine sand is added to the oil drilling waste.
  • water is added to the oil drilling waste.
  • the addition of water facilitates the pumping of the drilling waste.
  • the water is removed prior to the combustion or in conjunction with the mixing in a manner known per se, such as by separation by means of density, by sedimentation, centrifuging, or in some other manner.
  • the mixture ratio and/or additives of oil drilling waste of different types is adjusted.
  • the specific weight of the granules produced as a product is adjusted to be in the range 0.3 to 1.5 by changing the mixture ratio of the oil drilling waste of different types.
  • Granules with a low specific weight can be used e.g. for insulation.
  • granules with a high specific weight can be used e.g. as substitutes for building stone.
  • the size of the granules to be formed can vary. When desired, the granules can be screened to a desired size distribution for a given use.
  • the invention is based on an apparatus for processing oil drilling waste
  • the apparatus includes one or more feeding tanks; a rotating kiln, into which the oil drilling waste from the feeding tanks is introduced, and in which it is processed at a temperature of 1100 to 1350° C. to form compact-coated granules; and a storage tank, into which the granules from the kiln are stored; the feeding tank, kiln and storage tank are connected to form one whole.
  • the length of the rotating kiln is so selected that the process of the invention can be performed in the kiln using the desired process parameters, and that round-shaped granules can be formed in the kiln.
  • the rotation speed of the kiln can be used to adjust the size of the granules.
  • the apparatus includes a mixing device for mixing the oil drilling waste from the feeding tanks to form a homogenous mixture.
  • the apparatus includes at least one pump for pumping oil drilling waste, e.g. from the feeding tanks into the rotating kiln or from the feeding tank to the mixing device and/or from the mixing device into the rotating kiln.
  • the apparatus includes at least one conveyor for conveying the oil drilling waste from one part of the apparatus to another, e.g. from the feeding tank into the kiln; from the feeding tank to the mixing device; from the mixing device into the kiln; and/or from the kiln into the storage tank.
  • the heat produced in the kiln can be utilized as energy in conjunction with the processing of oil drilling waste, e.g. in conjunction with mixing, burning or the possible drying.
  • various devices known per se e.g. cyclone, exhaust fan, packed scrubber, interface scrubber, fan and/or drift eliminator or a similar device, are used for purifying and/or removing the combustion gases.
  • the apparatus is moveable, which reduces transportation costs.
  • the processing of oil drilling waste can be implemented near to a place where the oil drilling waste is produced, or near to a place where the granules to be formed are utilized.
  • the apparatus is integrated in conjunction with a vessel.
  • the feeding tank and the storage tank can be tanks of a vessel and the other parts of the apparatus have been disposed to a suitable place in the vessel.
  • the method and apparatus of the invention are suited for processing various kinds of waste produced in oil drilling.
  • the granules being produced can be utilized e.g. like sledgehammer gravel, in earth-moving, road building, as aggregate for building and construction industry, for special purposes, or in a similar manner.
  • the granules can be stored e.g. in an outdoor location or embedded in the sea bottom because due to the compact surface of the granules, there is nothing there to release into the water.
  • oil drilling waste is transformed into a form that is harmless to the environment.
  • the invention has the advantage that no additives or clay have to be added to the oil drilling waste for the processing of the invention. However, additives and/or clay can be added when desired.
  • the method of the invention is very environmentally friendly and contributes to the principle of sustainable development. Thanks to the invention, a product is obtained which can be made use of as recycled material and which fulfils the tightened environmental regulations.
  • FIG. 1 schematically represents one apparatus in accordance with the invention.
  • FIG. 1 shows an apparatus of the invention for processing oil drilling waste.
  • the apparatus of the FIGURE comprises two feedings tanks A and B; a mixing device 2 for mixing the oil drilling waste from the feeding tanks 1 to form a homogenous mixture; a rotating kiln 3 , into which the homogenous mixture is introduced, and in which the mixture is processed at a temperature of 1100 to 1350° C. to form granules with a compact coating; and a storage tank 4 , into which the product from the kiln is stored.
  • the storage tank 1 , the mixing device 2 , the kiln 3 , and the storage tank 4 are connected to form one whole.
  • the materials were plasticized and mixed to form a homogenous mixture using a so-called grain mill 2 .
  • the mixture batches were run 1 to 4 times through the mill 2 to obtain a homogenous mixture.
  • Each sample lot was run through a preheated kiln with a dwell time 1 to 1.5 hours.
  • a temperature in the range 1130-1150° C. was used.
  • the size of the granules formed varied in the range 5-25 mm.
  • the specific weight of the granules varied in the range 0.3-1.5.
  • combustion gas emissions were low, and different components were well within the limits.
  • the dwell time was observed to have an effect on the composition of the combustion gases.
  • the method and apparatus of the invention are suited to be used in the processing of various kinds of drilling waste.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Combustion & Propulsion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Fluid Mechanics (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Inorganic Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Soil Sciences (AREA)
  • Thermal Sciences (AREA)
  • Processing Of Solid Wastes (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

The invention relates to a method and apparatus for processing oil drilling waste. According to the invention, oil drilling waste of one or more types is selected, and is introduced from the feeding tanks into a rotating kiln; and in the kiln, the oil drilling waste is processed at a temperature of 110 to 13500° C. to form granules having a compact-coated surface.

Description

    FIELD OF THE INVENTION
  • The invention concerns a method defined in the preamble of claim 1 for processing oil drilling waste as well as an apparatus defined in the preamble of claim 12.
    • BACKGROUND OF THE INVENTION
  • At present, in oil drilling, deeper and deeper drillings are made and often so-called oblique drilling is used, which increases the amount of drilling waste. Furthermore in oil drilling, drilling fluid or lubricant is used, producing contaminated drilling waste that has been previously subjected to centrifuging or, treatment with heat at a temperature of less than 800° C. in order to purify it.
  • For example, in Norway, where a few percent of the world's oil fields are located, about 50,000 tonnes of oil drilling waste is produced annually.
  • The oil drilling waste of each object contains rock material and clay material in a ratio typical of each object.
  • Because environmental regulations are getting stricter, the problem with the prior-art methods is that using the present processing methods of oil drilling waste one cannot obtain a purified product that could be recycled. Using the present methods one has not been able to eliminate the problem with processing a big amount of oil drilling waste.
    • OBJECTIVE OF THE INVENTION
  • The objective of the invention is to eliminate the disadvantages referred to above. One specific objective of the invention is to disclose a new type of method and apparatus for processing the rock and clay-based material produced in oil drilling.
    • SUMMARY OF THE INVENTION
  • The method and apparatus of the invention are characterized by what is presented in the claims.
  • The invention is based on a method for processing oil drilling waste, especially for its further processing for the purposes of recycling. According to the invention, from one or more drilling objects, oil drilling waste of one or more types is selected, which wastes are introduced into a rotating kiln; in the kiln the oil drilling waste is processed, i.e. burned, at a temperature of 1100 to 1350° C. to form recyclable granules or granulates having a compact-coated, e.g. glazed, surface. In that case, agents harmful to the environment are removed; that is, they transform into another, chemically more harmless form and/or are adsorbed within the granular structure, meaning that the granules are neutralized with respect to the environmental detriments.
  • At the temperatures in accordance with the invention, a compact-coated surface such as a glazed surface is achieved for the granules.
  • Typically, oil drilling waste contains a rock derivative/rock derivatives; oil-based drilling fluid known per se; and in some cases also crude oil. The rock derivative may have been chosen from one of the following: illite, chlorite, kaolin, montmorillonite, chalkstone, sandstone, anhydrite, dolomite, calcite, or the like.
  • In one embodiment of the invention, the oil drilling waste is mixed to form a homogenous mixture prior to introducing into a rotating kiln. Mixing the agents to be processed to form a homogenous mixture prior to a combustion process increases the formation of granules with a uniform composition.
  • In one embodiment of the invention, the oil drilling waste is processed in the kiln at a temperature of 1120 to 1200° C.
  • In one embodiment, the oil drilling waste is processed in the kiln at a temperature of about 1130 to 1150° C. In one embodiment, the oil drilling waste is processed in the kiln at a temperature of more than 1150° C. to increase the adherence of the granules to one another.
  • As the adherence properties increase, the granules can be used e.g. directly in various cast use possibilities, including road soil, soil of storage areas, soil of pipelines, security areas of processes, and basins, or the like.
  • The oil drilling waste may contain 0 to 100% of rock material and/or 0 to 100% of clay material. In one embodiment, the oil drilling waste contains up to 70 to 100% of rock material and up to 30% of clay material.
  • In one embodiment of the invention, claybased material is added to the oil drilling waste.
  • In one embodiment of the invention, clay material such as marine sand is added to the oil drilling waste.
  • In one embodiment of the invention, water is added to the oil drilling waste. The addition of water facilitates the pumping of the drilling waste. Preferably, the water is removed prior to the combustion or in conjunction with the mixing in a manner known per se, such as by separation by means of density, by sedimentation, centrifuging, or in some other manner.
  • In one embodiment of the invention, the mixture ratio and/or additives of oil drilling waste of different types is adjusted.
  • In one embodiment of the invention, the specific weight of the granules produced as a product is adjusted to be in the range 0.3 to 1.5 by changing the mixture ratio of the oil drilling waste of different types. Granules with a low specific weight can be used e.g. for insulation. Correspondingly, granules with a high specific weight can be used e.g. as substitutes for building stone.
  • The size of the granules to be formed can vary. When desired, the granules can be screened to a desired size distribution for a given use.
  • In addition, the invention is based on an apparatus for processing oil drilling waste, According to the invention, the apparatus includes one or more feeding tanks; a rotating kiln, into which the oil drilling waste from the feeding tanks is introduced, and in which it is processed at a temperature of 1100 to 1350° C. to form compact-coated granules; and a storage tank, into which the granules from the kiln are stored; the feeding tank, kiln and storage tank are connected to form one whole.
  • In conjunction with the invention it is possible to use any rotating kiln known in prior art. Preferably, the length of the rotating kiln is so selected that the process of the invention can be performed in the kiln using the desired process parameters, and that round-shaped granules can be formed in the kiln. The rotation speed of the kiln can be used to adjust the size of the granules.
  • In one embodiment of the invention, the apparatus includes a mixing device for mixing the oil drilling waste from the feeding tanks to form a homogenous mixture.
  • In one embodiment of the invention, the apparatus includes at least one pump for pumping oil drilling waste, e.g. from the feeding tanks into the rotating kiln or from the feeding tank to the mixing device and/or from the mixing device into the rotating kiln.
  • In one embodiment of the invention, the apparatus includes at least one conveyor for conveying the oil drilling waste from one part of the apparatus to another, e.g. from the feeding tank into the kiln; from the feeding tank to the mixing device; from the mixing device into the kiln; and/or from the kiln into the storage tank.
  • In one embodiment, it is possible to use afterburning in conjunction with the processing of oil drilling waste.
  • In a preferred embodiment, the heat produced in the kiln can be utilized as energy in conjunction with the processing of oil drilling waste, e.g. in conjunction with mixing, burning or the possible drying.
  • In one embodiment, various devices known per se, e.g. cyclone, exhaust fan, packed scrubber, interface scrubber, fan and/or drift eliminator or a similar device, are used for purifying and/or removing the combustion gases.
  • In one embodiment of the invention, the apparatus is moveable, which reduces transportation costs. In that case, the processing of oil drilling waste can be implemented near to a place where the oil drilling waste is produced, or near to a place where the granules to be formed are utilized.
  • In one embodiment of the invention, the apparatus is integrated in conjunction with a vessel. In that case, the feeding tank and the storage tank can be tanks of a vessel and the other parts of the apparatus have been disposed to a suitable place in the vessel. The advantage is that the intermediate costs and therefore the transportation costs are reduced.
  • The method and apparatus of the invention are suited for processing various kinds of waste produced in oil drilling. The granules being produced can be utilized e.g. like sledgehammer gravel, in earth-moving, road building, as aggregate for building and construction industry, for special purposes, or in a similar manner. Alternatively, the granules can be stored e.g. in an outdoor location or embedded in the sea bottom because due to the compact surface of the granules, there is nothing there to release into the water.
  • Thanks to the invention, oil drilling waste is transformed into a form that is harmless to the environment.
  • The invention has the advantage that no additives or clay have to be added to the oil drilling waste for the processing of the invention. However, additives and/or clay can be added when desired.
  • With the method and apparatus of the invention, producing of granules is very cost-effective. It is possible to dispose of oil drilling waste while obtaining material to be recycled and, as a by-product, energy. The method and apparatus of the invention are very simple, which reduces investment and processing costs. Devices known per se can be used in the apparatus.
  • The method of the invention is very environmentally friendly and contributes to the principle of sustainable development. Thanks to the invention, a product is obtained which can be made use of as recycled material and which fulfils the tightened environmental regulations.
    • LIST OF FIGURES
  • The invention will now be explained by means of detailed examples of its embodiments with reference to the accompanying drawing, in which
  • FIG. 1 schematically represents one apparatus in accordance with the invention.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • FIG. 1 shows an apparatus of the invention for processing oil drilling waste. The apparatus of the FIGURE comprises two feedings tanks A and B; a mixing device 2 for mixing the oil drilling waste from the feeding tanks 1 to form a homogenous mixture; a rotating kiln 3, into which the homogenous mixture is introduced, and in which the mixture is processed at a temperature of 1100 to 1350° C. to form granules with a compact coating; and a storage tank 4, into which the product from the kiln is stored. The storage tank 1, the mixing device 2, the kiln 3, and the storage tank 4 are connected to form one whole.
    • Example 1
  • The tests of the examples used rock-rich oil drilling waste A from Norway. Part of the tests used, in addition, clay B, which was mixed with A.
  • In the tests, the materials were plasticized and mixed to form a homogenous mixture using a so-called grain mill 2. The mixture batches were run 1 to 4 times through the mill 2 to obtain a homogenous mixture.
  • Each sample was 30 kg. The mixture ratios are shown below:
      • A without plasticization=A0
      • A mixed=A00
      • A+B=20%+80%=A20B80
      • A+B=40%+60%=A40B60
      • A+B=50%+50%=A50B50
      • A+B=60%+40%=A60B40
      • A+B=80%+20%=A80B20
  • 4 pieces of samples were obtained from each mixture. The samples that were mixed to be homogenous were introduced into a rotating kiln 3, which was a pilot kiln with a ratio 1:12. The kiln had a ceramic interior. The temperature was adjusted by means of gas.
  • Each sample lot was run through a preheated kiln with a dwell time 1 to 1.5 hours. As the combustion temperature, a temperature in the range 1130-1150° C. was used.
  • As a result of the combustion, round-shaped, compact-coated granules were obtained which were analyzed for detrimental agents, such as heavy metals, and for solubility. It was observed that the detrimental agents had changed chemically, had removed during the combustion, and bound to the granular structure, whereby from an environmental standpoint, a neutral product was obtained.
  • The size of the granules formed varied in the range 5-25 mm. The specific weight of the granules varied in the range 0.3-1.5.
  • From the solubility tests it was observed that the solubility of different agents and metals was below the limits set by the authorities.
  • In addition, it was found that barium sulphate had transformed into non-detrimental barium and sulphur compounds during the process, which was an additional advantage for it invention.
  • In addition, combustion gas emissions were low, and different components were well within the limits. The dwell time was observed to have an effect on the composition of the combustion gases.
  • In addition, a test run was run near the melting point for samples A50B50, A0, and A00. Then, a temperature of about 1180° C. was found to be suitable, at which temperature suitable adherence properties are achieved for the granules.
  • As a summation of the tests one can see that with different mixture ratios of oil drilling waste, recyclable, compact-coated granules which are non-detrimental to the environment were obtained. In addition, it was observed that burning the hydrocarbons, contained in oil drilling waste, in the kiln reduced the need for external heating energy.
  • In the form of various embodiments, the method and apparatus of the invention are suited to be used in the processing of various kinds of drilling waste.
  • The embodiments of the invention are not limited to the examples presented above, but they can vary within the scope of the attached claims.

Claims (17)

1. A method for processing oil drilling waste, wherein oil drilling waste of one or more types is selected, which waste is introduced into a rotating kiln; and in the kiln, the oil drilling waste is processed at a temperature of 1100 to 1350° C. to form granules having a compact-coated surface.
2. The method as defined in claim 1, wherein the oil drilling waste is mixed to form a homogenous mixture prior to introduction into the rotating kiln.
3. The method as defined in claim 1, wherein in the kiln, the oil drilling waste is processed at a temperature of 1120 to 1200° C.
4. The method as defined in claim 3, wherein in the kiln, the oil drilling waste is processed at a temperature of 1130 to 115O° C.
5. The method as defined in claim 3, wherein in the kiln, the oil drilling waste is processed at a temperature of more than 1150° C. to add to the adherence of the granules to one another.
6. The method as defined in claim 1, wherein clay-based material is added to the oil drilling waste.
7. The method as defined in claim 1, wherein sand material is added to the oil drilling material.
8. The method as defined in claim 1, wherein water is added to the oil drilling waste.
9. The method as defined in claim 1, wherein the water is removed from the oil drilling waste prior to the rotating kiln.
10. The method as defined in claim 1, wherein in the method, the mixture ratio and/or additives of different types of oil drilling waste is adjusted.
11. The method as defined in claim 1, wherein the specific weight of the granules produced as a product is adjusted to be in the range 0.3-1.5 by changing the mixture ratio of different types of oil drilling waste.
12. An apparatus for processing oil drilling waste, wherein the apparatus includes one or more feeding tanks; a rotating kiln, into which the oil drilling waste from the feeding tanks is introduced, and in which it is processed at a temperature of 1100 to 1350° C. to form compact-coated granules; and a storage tank, into which the product from the kiln is stored; with the feeding tank, the kiln and the storage tank being connected to form one whole.
13. The apparatus as defined in claim 12, wherein the apparatus in-eludes a mixing device for mixing the oil drilling waste from the feeding tank to form a homogenous mixture.
14. The apparatus as defined in claim 12, that wherein the apparatus in-eludes at least one pump for pumping the oil drilling waste.
15. The apparatus as defined in claim 12, wherein the apparatus includes at least one conveyor for conveying the oil drilling waste from one part of the apparatus to another.
16. The apparatus as defined in claim 12, wherein the apparatus is moveable.
17. The apparatus as defined in claim 12, wherein the apparatus is integrated in conjunction with a vessel.
US12/442,891 2006-09-25 2007-09-25 Method and apparatus for processing oil drilling waste Abandoned US20100112505A1 (en)

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FI20060849A FI20060849A7 (en) 2006-09-25 2006-09-25 Method and apparatus for treating oil drilling waste
PCT/FI2007/050514 WO2008037851A1 (en) 2006-09-25 2007-09-25 Method and apparatus for processing oil drilling waste

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GB2522619A (en) * 2014-01-25 2015-08-05 John Barnfather A method of using a rotary kiln and associated apparatus for waste disposal and product manufacture
RU2630908C1 (en) * 2016-05-06 2017-09-14 Антон Евгеньевич Машкин Mobile plant for drilling waste processing
CN112062542A (en) * 2020-08-31 2020-12-11 杨明儒 Building material product made of drilling solid waste

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FI20060849L (en) 2008-03-26
CA2664422A1 (en) 2008-04-03
RU2009111341A (en) 2010-11-10
FI20060849A0 (en) 2006-09-25
WO2008037851A1 (en) 2008-04-03
NO20091589L (en) 2009-04-22
FI20060849A7 (en) 2008-03-26
EP2081702A1 (en) 2009-07-29

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